Box and method of constructing the same

ABSTRACT

A box suitable for the packaging of a consumer product is formed by helically wrapping an elongated continuous strip of material around a mandrel to form a main body with a plurality of bands. In one embodiment, adjacent bands partially overlie one another to form a multi-paneled main body with an open top end and an open bottom end. An adhesive is disposed within the region of contact between adjacent bands to retain the shape of the main body. First and second sets of slots are formed in the main body to create flaps dimensioned to selectively enclose the open top and bottom ends, respectively. To define the flaps and promote pivotal articulation, the main body is also preferably provided with score lines. By adjusting the configuration of the mandrel, a customized box can be constructed that is sized to receive a consumer product with limited wasted space.

FIELD OF THE INVENTION

The present invention relates generally to the packaging and shipment ofconsumer products and, more particularly, to boxes used in the packagingand shipment of consumer products.

BACKGROUND OF THE INVENTION

The proliferation of e-commerce has created a commensurate increase inneed for packaging solutions that are appropriate in the shipment ofconsumer products. Nonetheless, despite the growing demand for effectiveshipment packaging, online purchase fulfillment remains most commonlyprocessed using single-use, fixed-size boxes.

E-commerce shipment boxes are most commonly constructed from apreformed, unitary blank that is constructed of a rigid, durable andinexpensive material, such as cardboard or plastic. The blank is shapedto define a plurality of panels that are typically separated by areas ofweakness, such as fold lines. Accordingly, as part of the assemblyprocess, the blank is folded about the fold lines to erect the box, withthe shape secured through the use of interlocking panels and/or anadhesive.

Although well-known and widely used in the art, boxes formed from apreformed blank, as described above, suffer from a notable drawback.Notably, boxes formed from a preformed blank are fixed in size andthereby incapable of dimensional variability. However, due to the nearlimitless variety of different products currently available online,packaging requirements can vary considerably depending upon the size andshape of the items ultimately shipped to the purchaser.

As a result, online businesses and e-commerce fulfillment centers oftenmaintain a comprehensive inventory of differently dimensioned boxes.Yet, it has been found that online purchase fulfillment remains largelyincapable of packaging and shipping products within anappropriately-sized box. Rather, current studies have indicated onlinepurchases are most commonly packaged in an inefficient fashion, with theaverage e-commerce package containing approximately 40% of empty, orvoid, space.

The aforementioned inefficiency in the packaging of products orderedonline has been found to create a number of notable shortcomings.

As a first shortcoming, the use of a container that is considerablylarger than the products packaged therein results in a correspondingincrease in packaging costs. In particular, a greater amount of materialis required to form the box itself, with the amount of excess packagingmaterial often exceeding 15% of the amount of corresponding materialrequired to construct an ideally-sized package. Additionally, asubstantial about of package filler is typically needed to fill in theempty space within a conventional e-commerce box to prevent productmovement and potential damage during shipment, with the amount of excesspackage filler often exceeding 60% of the amount of correspondingpackage filler needed in an ideally-sized package.

As a second shortcoming, the use of a container that is considerablylarger than the products packaged therein results in a correspondingincrease in transportation costs. Notably, storage and delivery costsare typically directly proportional to the size and/or weight of ashipped item. Therefore, an unnecessarily oversized package createstransportation inefficiencies (i.e. increased weight and smallerpayloads) for couriers that are, in turn, often financially borne by theconsumer. In fact, it has been found that the transportation costassociated with traditional, inefficiently-sized, e-commerce packagesoften exceeds 20% of the corresponding transportation cost for anideally-sized package.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a new and improved box foruse in the packaging and shipment of consumer products.

It is another object of the present invention to provide a box asdescribed above that can be modified dimensionally to receive consumerproducts with limited wasted space.

It is yet another object of the present invention to provide a box asdescribed above that has a limited number of parts, is inexpensive tomanufacture and is easy to use.

Accordingly, as a feature of the invention, there is provided a box,comprising (a) a continuous strip wound in a helical configuration so asto define a main body with a plurality of bands, (b) wherein adjacentbands are coupled together to render the main body unitary inconstruction.

As another feature of the invention, there is provided a method ofconstructing a box, the method comprising the steps of (a) winding acontinuous strip in a helical configuration so as to define a main bodywith a plurality of bands, and (b) coupling together adjacent bands tosecure the shape of the main body.

Various other features and advantages will appear from the descriptionto follow. In the description, reference is made to the accompanyingdrawings which form a part thereof, and in which is shown by way ofillustration, an embodiment for practicing the invention. The embodimentwill be described in sufficient detail to enable those skilled in theart to practice the invention, and it is to be understood that otherembodiments may be utilized and that structural changes may be madewithout departing from the scope of the invention. The followingdetailed description is therefore, not to be taken in a limiting sense,and the scope of the present invention is best defined by the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein like reference numerals represent like parts:

FIG. 1(a) is a top perspective view of a first embodiment of a boxconstructed according to the teachings of the present invention, the boxbeing shown with its top and bottom flaps positioned open;

FIG. 1(b) is an enlarged, fragmentary, perspective view of the box shownin FIG. 1(a), taken within circled region A to more closely illustrateone of the vertical slots in the box body;

FIGS. 2(a) and 2(b) are front plan and left side views, respectively, ofthe box shown in FIG. 1(a) at an intermediary stage of its construction,the box being shown with a limited selection of its partiallyoverlapping bands for ease of illustration;

FIG. 3 is an enlarged, fragmentary, left end view of the box shown inFIG. 2(b), taken within circled region B to more closely illustrate thehelical arrangement between adjacent bands of the box body;

FIG. 4 is top perspective view an adjustable size-mandrel that isdesigned to facilitate construction of the box shown in FIG. 1;

FIG. 5 is a top perspective view of the box shown in FIG. 1 at anintermediary stage of its construction;

FIGS. 6(a) and 6(b) are front plan and right-side views, respectively,of the box shown in FIG. 1, the box being shown with score lines to moreclosely illustrate the pivotability of top and bottom flaps;

FIG. 7 is an enlarged, fragmentary, front plan view of the box shown inFIG. 6(a), taken within circled region C to more closely illustrate thedetails of one of the score lines;

FIGS. 8(a) and 8(b) are front plan and left side views, respectively, ofa second embodiment of a box constructed according to the teachings ofthe present invention, the box being shown at an intermediary stage ofits construction for ease of illustration;

FIG. 9 is an enlarged, fragmentary, left end view of the box shown inFIG. 8(b), taken within circled region D to more closely illustrate thealternative means for securing adjacent bands of the box body;

FIGS. 10(a) and 10(b) are front plan and left side views, respectively,of a third embodiment of a box constructed according to the teachings ofthe present invention, the box being shown at an intermediary stage ofits construction for ease of illustration;

FIG. 11 is an enlarged, fragmentary, left end view of the box shown inFIG. 10(b), taken within circled region E to more closely illustrate analternative interface between adjacent bands of the box body;

FIGS. 12(a) and 12(b) are front plan and left side views, respectively,of a fourth embodiment of a box constructed according to the teachingsof the present invention, the box being shown at an intermediary stageof its construction for ease of illustration;

FIG. 13 is an enlarged, fragmentary, left end view of the box shown inFIG. 12(b), taken within circled region F to more closely illustrate analternative, interlocking-type interface between adjacent bands of thebox body;

FIGS. 14(a)-(c) are rear perspective, rear plan, and left end views,respectively, of a strip of material constructed according to theteachings of the present invention, the strip of material beingparticularly well suited for use in constructing a box through a helicalwinding process;

FIG. 15 is a left end, section view of a box panel formed using thestrip of material shown in FIG. 14(a), wherein adjacent bands are showsslightly spaced apart for ease of illustration; and

FIGS. 16(a)-(f) are a series of top, right side, perspective views ofthe box body shown in FIG. 5 at various stages of enclosing its open topusing a creasing technique to form a set of top panels.

DETAILED DESCRIPTION OF THE INVENTION Box 11

Referring now to FIG. 1(a), there is shown a first embodiment of a boxconstructed according to the teachings of the present invention, the boxbeing defined generally by reference numeral 11. As will be explained indetail below, box 11 is uniquely designed to allow for dimensionalvariability during its construction and thereby receive a wide varietyof different consumer products with limited wasted space, which is aprincipal object of the present invention. In this manner, the size andshape of box 11 can essentially be customized for the particularconsumer products to be retained therein.

As defined herein, the term “box” denotes any enclosable packaging thatis appropriately configured to store and transport one or more consumerproducts without any restriction to shape, size or material. Forinstance, use of the term “box” herein is not restricted to a containerin the shape of a polyhedron (i.e. formed with multiple planar faces),but rather encompasses all conceivable packaging configurations, such astubular packaging boxes and envelope-type shipping containers.

Box 11 comprises an elongated, continuous strip 13 that is constructedof a rigid and durable material suitable for use in packagingapplications, such as a heavy-duty, paper-based, packaging material(e.g. cardboard) or plastic. Notably, strip 13 may be formed using acorrugated cardboard material to provide box 11 with an adequate degreeof structural integrity and strength, as will be explained further indetail below.

Strip 13 is wound counterclockwise in a helical configuration to form aunitary box, or main body 15, with a plurality of individual bands, orturns, 17. In the present embodiment, box body 15 is represented ascomprising eight separate bands 17-1 thru 17-8. However, as will beexplained in detail below, the number of turns 17 is selected based uponthe desired height of box 11 (i.e. to fittingly receive the intendedproduct to be packaged) and, as such, is intended to be modified to suitthe particular needs of the intended application.

As defined herein, the term “helical” denotes that strip 13 is wrappedabout a common central axis, in either a clockwise or counterclockwisedirection, to form three-dimensional box body 15. The resultant box body15 achieved from the helical wrapping of strip 13 can therefore includeregions that are flattened and/or curved in any representation.

In the present embodiment, box body 15 is a four-sided member comprisinga front panel 19-1, a rear panel 19-2, a first side panel 19-3 and asecond side panel 19-4 that together define an interior cavity 21 thatcan be accessed through an open top end 23 and/or an open bottom end 25.As will be explained further below, box body 15 is slotted and scored soas to define a set of top flaps 27 configured to selectively encloseopen top end 23 and a set of bottom flaps 29 configured to selectivelyenclose open bottom end 25.

Referring now to FIGS. 2(a) and 2(b), strip 13 comprises a flattenedfront surface 31, a flattened rear surface 33, a narrow top edge 35 anda narrow bottom edge 37. As shown herein, strip 13 is preferably ofuniform thickness along the majority of its length. However, as will beexplained further below, the leading and trail ends of strip 13 arepreferably cut, or otherwise tapered, to render both (i) the distal edgeof all top flaps 27 generally coplanar, and (ii) the distal edge of allbottom flaps 29 generally coplanar.

As seen most clearly in FIG. 3, each successive, or adjacent, band 17partially overlies its predecessor. For instance, as shown herein, band17-4 partially overlies band 17-3, with rear surface 33 of band 17-4along its bottom edge 37 in contact with front surface 31 of band 17-3along its top edge 35. In this manner, further helical winding of strap13 can be performed, as needed, to construct box 11 at the desiredheight.

It should be noted that both the width of strip 13 as well as the degreeof overlap between successive bands 17 can be modified, as needed, toattain the panel strength and visual appearance required for thedesignated application.

As shown, an adhesive 41 is preferably disposed within the region ofcontact between adjacent bands 17 of box body 15. In this manner, theadhesive bond established between adjacent bands 17 fixedly secures boxbody 15 in the desired shape.

In the present embodiment, adhesive 41 is preferably in the form of aquick-dry adhesive that is applied as a thin continuous strip onto frontsurface 31 along top edge 35 during the strip dispensing process, asseen most clearly in FIGS. 2(a) and 2(b). However, it is to beunderstood that adhesive 41 represents any type bonding substance thatcan be used to facilitate construction of box 11. For instance, adhesive41 may alternatively be in the form of a pressure-sensitive adhesivethat is coated onto front surface 31 of strip 13 along top edge 35 atthe time of its manufacture. In this scenario, adhesive 41 would onlyactivate when adjacent bands 17 are drawn into contact with one anotherunder sufficient pressure (e.g. during the helical winding process). Asanother example, adhesive 41 may be in the form of a water-activatedadhesive.

Method of Constructing Box 11

Due to its unique method of construction, box 11 can be customized inconfiguration to receive a wide variety of different consumer productswith limited wasted space. The preferred sequence of steps in theprocess of constructing box 11 is set forth in detail below.

Specifically, as the first step in the process of constructing box 11, asupply of material strip 13 is provided. As referenced above, strip 13is preferably constructed out of any heavy-duty material that issuitable for use in the packaging of consumer products. To facilitatedispensing and minimize storage requirements, material strip 13 ispreferably supplied in the form of a relatively compact reel (notshown).

Next, a mandrel, or form, is utilized to define the basic geometricconfiguration of the box to be constructed. Referring now to FIG. 4, asize-adjustable mandrel 51 is shown that includes a plurality ofvertical posts, or towers, 53 that define the general footprint of thedesired box 11 (i.e. towers 53 define the location of the inner cornersof box 11). Preferably, each post 53 is capable of being individuallydisplaced relative to the remaining posts 53 in multiple directions tocreate a virtually boundless variety of potential box configurations.

However, it should be noted that the box construction process of thepresent invention is not limited to size-adjustable mandrel 51. Rather,the box construction process of the present invention could beimplemented using any type of mandrel, whether fixed in size orreconfigurable, without departing from the spirit of the presentinvention. Accordingly, it is to be understood, that size-adjustablemandrel 51 is provided herein for illustrative purposes only and anyreference herein is strictly to assist in the understanding of the novelbox construction process.

To commence the box forming process, strip 13 is wound around mandrel 51in a helical configuration, as shown in FIG. 4, to create box body 15with bands 17. As referenced previously, quick-dry adhesive 41 ispreferably applied to front surface 31 of strip 13 along top edge 35immediately prior to the helical winding process (e.g. after initialdispensing from a reel) to secure the shape of main body 15.

In the present embodiment, successive bands 17 are disposed to overlieone another through a region of contact, with successive bands 17 beingbonded together by adhesive 41 disposed therebetween. However, as willbe explained further in detail below, adjacent bands 17 could bealternatively arranged (i.e. in a non-overlapping fashion) withoutdeparting from the spirit of the present invention. Additionally, itshould be briefly noted that alternative and/or supplemental means forsecuring adjacent bands 17 could be implemented to fix the shape of boxbody 15, as will be explained further in detail below.

Once box body 15 is of a height suitable for the consumer products to bepackaged therein (while compensating for the width of top and bottomflaps 27 and 29 to be subsequently formed therefrom), strip 13 is cutfrom the remainder of its supply reel. Thereafter, leading end 13-1 andtrail end 13-2 are preferably trimmed (i.e. tapered in width) to form anarrow wedge-like tip, as seen most clearly in FIG. 5. In this manner,each of open top end 23 and open bottom end 25 of box body 15 isrendered generally coplanar, the benefit of which will become apparentbelow.

With box body 15 formed in the manner set forth above, vertical slotsare formed in box body 15 to create flaps for selectively enclosing opentop end 23 and open bottom end 25. Specifically, referring back to FIGS.1(a) and 1(b), a first set of vertical slots 61-1 is formed in open topend 23 of box body 15 at the juncture, or corner, of adjacent panels 19.Similarly, a second set of vertical slots 61-2 is formed in open bottomend 23 of box body 15 at the juncture, or corner, of adjacent panels 19.

In this manner, box 11 is constructed to include front panel 19-1, rearpanel 19-2, first side panel 19-3 and second side panel 19-4 whichtogether define an interior cavity 21 that is accessible through eitheropen top end 23 or open bottom end 25. Additionally, box 11 includes setof pivotable top flaps 27-1 thru 27-4 which are dimensioned toselectively enclose open top end 23 and set of pivotable bottom flaps29-1 thru 29-4 which are dimensioned to selectively enclose bottom end25, the entire set of flaps 27 and 29 being illustrated in FIGS. 6(a)and 6(b).

As seen most clearly in FIG. 1(b), each slot 61 is of a fixed depth Dthat is suitable for creating appropriately dimensioned flaps 27 and 29.Also, each slot 61 is preferably of a width W that prevents interferencebetween adjacent top and bottom flaps 27 and 29, while, at the sametime, ensures adequate enclosure of open top and bottom ends 23 and 25when pivoted closed.

Referring now to FIGS. 6(a), 6(b) and 7, a horizontal notch 63,generally C-shaped in lateral cross-section, is formed in the exteriorof box body 15 as a line separating, or defining, the proximal edge ofeach of flaps 27 and 29 from its adjacent panel 19 (i.e. linearlybetween the terminal ends of adjacent upper and lower slots 61). Assuch, each linear notch, or score line, 63 creates a region of weaknesswhich facilitates folding of flaps 27 and 29.

In the present embodiment, box 11 is represented as a regular slottedcontainer, or RSC, wherein (i) top flaps 27-1 thru 27-4 are of the samesize and shape as bottom flaps 29-1 thru 29-4, respectively, and (ii)each pair of outer lengthwise flaps (i.e. top flap pair 27-1 and 27-3 aswell as bottom flap pair 29-1 and 29-3) are one-half of the width of box11 and thereby align in abutment at the center of its corresponding boxopening. However, it is to be understood that box 11 is not limited toany particular flap style. Rather, box body 15 could be cut and scoredto define alternative flap styles without departing from the spirit ofthe present invention.

Upon completion of the aforementioned slotting and scoring processes,the outer dimensions, or footprint, of mandrel 51 is temporarilycontracted to the extent necessary that box 11 can be easily removedtherefrom. Thereafter, to package the desired products within box 11,bottom flaps 29 are first pivoted closed and are, in turn, securedtogether using a suitable adhesive, such as tape. The desired product isthen deposited within interior cavity 21 through open top end 23. Due tothe customized sizing of box 11, interior cavity 21 is dimensioned tofittingly receive the product with minimal excess space. Afterwards, topflaps 27 are pivoted closed and secured together with a suitableadhesive material, thereby completing the customized packaging of thedesignated product.

Alternate Embodiments and Design Modifications

The invention described in detail above is intended to be merelyexemplary and those skilled in the art shall be able to make numerousvariations and modifications to it without departing from the spirit ofthe present invention. All such variations and modifications areintended to be within the scope of the present invention as defined inthe appended claims.

For instance, it should be noted that box 11 is not limited to the useof an adhesive 41 disposed between overlapped regions of adjacent bands17 to secure the shape of box body 15. Rather, supplemental orreplacement means for securing the shape of box body 15 could beimplemented without departing from the spirit of the present invention.

Notably, referring now to FIGS. 8(a) 8(b), and 9, there is shown asecond embodiment of a box constructed according to the teachings of thepresent invention, the box being identified generally by referencenumeral 111. As can be seen, box 111 is similar to box 11 in that box111 comprises a material strip 113 that is wound in a helicalconfiguration to form a box body 115 with partially overlapping bands117-1 thru 117-4. However, box 111 differs from box 11 in that, in placeof adhesive 41, the shape of box body 115 is secured using externallyapplied lengths of tape 119. For instance, as seen most clearly in FIG.9, first and second lengths of tape 119-1 and 119-2 are applied to theinterior and exterior panel surfaces, respectively, of box body 115 overadjacent bands 117-3 and 117-4. As can be appreciated, tape 119 not onlyhelps secure the shape of box body 115 but also provides the addedbenefit of smoothing out the interior and exterior panel surfaces of boxbody 115 (i.e. creating a smoothened surface across the overlappedregion of successive bands 117).

Furthermore, in lieu of an adhesive, alternative means for securingtogether adjacent bands 117 of box body 115 could be achieved withoutdeparting from the spirit of the present invention. For example, ifstrip 113 is formed using a plastic material, localized ultrasonicwelding may be applied within the region of contact between adjacentbands 117 to create a permanent bond therebetween.

Additionally, it should be noted that box 11 need not be constructedwith successive bands 17 arranged in a partially overlappingconfiguration. Rather, the interface between adjacent bands 17 of boxbody 15 could be modified without departing from the spirit of thepresent invention.

For example, referring now to FIGS. 10(a), 10(b) and 11, there is showna third embodiment of a box constructed according to the teachings ofthe present invention, the box being identified generally by referencenumeral 211. As can be seen, box 211 is similar to box 111 in that box211 comprises a material strip 213 that is wound in a helicalconfiguration to form a box body 215 with a plurality of bands 217-1thru 217-4. However, box 211 differs from box 111 in the nature of theinterface, or contact region, between adjacent bands 217.

Specifically, in lieu of a partially overlapping interface betweenadjacent bands, box body 215 is formed by disposing each successive band217 in direct vertical alignment with its predecessor to create asubstantially planar, panel wall surface, as shown in FIG. 10(b). Inother words, as seen most clearly in FIG. 11, bottom edge 219 of band217-4 is disposed in direct contact against top edge 221 of previousband 217-3 such that interior surface 223 and exterior surface 225 ofall bands 217 within a panel of box body 215 lie generally flush withone another (i.e. in coplanar alignment). Arranged as such, first andsecond bands of tape 229-1 and 229-2 are preferably applied to theinterior surface 223 and exterior surface 225, respectively, of box body215 across adjacent bands 217 to secure the shape of box body 215.

It should be noted that material strip 213 may be modified to ensureproper alignment between adjacent bands 217 which are vertically alignedin the manner set forth in FIGS. 10(a), 10(b) and 11. Notably, referringnow to FIGS. 12(a), 12(b) and 13, there is shown a fourth embodiment ofa box constructed according to the teachings of the present invention,the box being identified generally by reference numeral 311. As can beseen, box 311 is similar to box 211 in that box 311 comprises a materialstrip 313 that is wound in a helical configuration to form a box body315 with a plurality of bands 317-1 thru 317-4, whereby each successiveband 317 is positioned in direct vertical alignment with its predecessorto create a substantially planar wall surface, as shown in FIG. 12(b).However, box 311 differs from box 211 in that material strip 313 ismodified to create a unique mating, or interlocking, relationship withinthe region of contact between successive bands 317.

Specifically, as seen most clearly in FIG. 13, material strip 313includes a bottom edge 319 and a top edge 321 with complementary steppedsurfaces. Accordingly, during formation of box 311, bottom edge 319 ofeach band 317 matingly engages top edge 321 of its predecessor. Oncearranged as such, first and second bands of tape 329-1 and 329-2 arepreferably applied to the interior surface 323 and exterior surface 325,respectively, of box body 315 across adjacent bands 317 to secure theshape of box body 315.

As can be appreciated, the unique, interlocking mating relationshipbetween top edge 321 of a first band 317 (e.g. band 317-3) and bottomedge 319 of the next successive band (e.g. band 317-4) ensures properalignment between adjacent bands 317, thereby resulting in a flush, orcoplanar, interior panel surface 323 as well as a flush, or coplanar,exterior panel surface 325. Additionally, the interlocking relationshipbetween top edge 321 of a first band 317 and bottom edge 319 of the nextsuccessive band serves to increase the connective strength betweenadjacent bands 317 as compared to previous embodiments.

It should be noted that a corrugated version of material strip 313 couldbe implemented to provide box body 313 with adequate strength andrigidity for conventional shipping applications. For instance, referringnow to FIGS. 14(a)-(c), there is shown a corrugated material strip 413that is particularly well-suited for use in forming box body 313.

Specifically, material strip 413 comprises first and second linerboards415-1 and 415-2 between which is disposed a corrugated layer 417. Aswill be explained further in detail below, each of linerboards 415extends beyond an opposing edge of corrugated layer 417 to create anextension, or lip, that overlies the seam between adjacent layers ofstrip 413 when wound in a helical configuration.

Each of linerboards 415 is preferably constructed from a generallyplanar sheet of paper-based material. As such, first linerboard 415-1comprises a top edge 419-1, a bottom edge 421-1, a front surface 423-1and a rear surface 425-1. Similarly, second linerboard 415-2 comprises atop edge 419-2, a bottom edge 421-2, a front surface 423-2 and a rearsurface 425-2.

Corrugated layer 417 is constructed from a sheet of fluted material thataffords strip 413 with the necessary rigidity and durability for routinepackaging applications. Corrugated layer 417 comprises a top edge 427, abottom edge 429, a front surface 431 and a rear surface 433. As seenmost clearly in FIG. 14(c), corrugated layer 417 is sandwiched directlybetween first and second linerboards 415-1 and 415-2 and is permanentlysecured thereto with a suitable adhesive (not shown) to render materialstrip 413 a unitary item.

As a feature of the present invention, top edge 419-1 of firstlinerboard 415-1 extends beyond top edge 427 of corrugated layer 417.Similarly, bottom edge 421-2 of second linerboard 415-2 extends beyondbottom edge 429 of corrugated layer 417. At the same time, bottom edge421-1 of first linerboard 415-1 lies generally flush with bottom edge429 of corrugated layer 417 and top edge 419-2 of second linerboard415-2 lies generally flush with top edge 427 of corrugated layer 417.

As a result, top edge 419-1 of first linerboard 415-1 and bottom edge421-2 of second linerboard 415-2 form extensions that allow for a nearseamless vertical abutment of successive bands when material strip 413is wound in a helical configuration. In particular, as shown in FIG. 15,with strip 413 helically wrapped as a plurality of vertically alignedbands, top edge 419-1 of linerboard 415-1 for a first band of material413-1 overlies the seam, or junction, between a second band of material413-2 disposed in direct vertical alignment therewith. Additionally,bottom edge 421-2 of linerboard 415-2 for second band of material 413-2overlies the seam with first band of material 413-1 upon the opposingsurface. As such, the junction between bands 413-1 and 413-2 is renderedclean and seamless.

It should be noted that strip 413 is not limited to a construction witha single corrugated layer. Rather, it is to be understood that strip 413could incorporate additional corrugated layers, each disposed directlybetween an adjacent pair of linerboards, without departing from thespirit of the present invention. However, it should be noted that ineach implementation with multiple corrugated walls, the outermostlinerboards preferably include opposing, offset extensions to allow forseamless vertical abutment of successive bands when the material stripis wound in a helical configuration.

Lastly, it should be noted that the present invention is not limited tothe use of vertical slots 61 to define top and bottom sets of flaps 27and 29 in box body 15. Rather, alternative means for forming top andbottom flaps 27 and 29 in box body 15 could be implemented withoutdeparting from the spirit of the present invention. For instance, aseries of creases could be incorporated into box body 15 to create areasof weakness through which box body 15 can be folded to create flapscapable of enclosing open top end 23 and/or an open bottom end 25.

More specifically, as shown in FIG. 16(a), a series of contiguous,horizontal, linear creases 511-1 can be formed in each panel 19 of boxbody 15 to create a set of top flaps 527-1 thru 527-4 which are designedto selectively enclose open top end 23. Additionally, a pair of diagonalcreases 511-2 is formed in opposing side flaps 527-3 and 527-4. As seenmost clearly in FIGS. 16(b)-(d), creases 511-2 enable small flaps 527-3and 527-4 to fold inward, or collapse. In this capacity, long flaps527-1 and 527-2 are able to pivot inward. As seen most clearly in FIGS.16(e) and 16(f), long flaps 527-1 and 527-2 are suitably dimensioned toenclose open top end 23 of box body 15.

For ease of illustration only, the creasing technique described indetail above is applied to box body 15 to enclose open top end 23.However, it is to be understood that a similar creasing technique couldbe applied to box body 15 to enclose open bottom end 25 withoutdeparting from the spirit of the present invention.

What is claimed is:
 1. A box, consisting of: (a) a single continuousstrip wound in a helical configuration so as to define a main body and aplurality of flaps, the main body including a plurality of bands, andeach of the plurality of flaps including at least a portion of a band;(b) wherein adjacent bands are coupled together to render the main bodyunitary in construction.
 2. The box as claimed in claim 1 wherein thesingle continuous strip comprises a layer of corrugated material that isdisposed between a first layer of material and a second layer ofmaterial.
 3. The box as claimed in claimed in claim 2 wherein the firstlayer of material is arranged to form a lip that overlies a seam ofadjacent ones of the plurality of bands when the single continuous stripis wound in the helical configuration so as to define the main body. 4.The box as claimed in claim 2 wherein adjacent bands of the main bodyare in contact with one another and engage with one another through amating interface.
 5. The box as claimed in claim 4 wherein adjacentbands of the main body are partially overlapping.
 6. The box as claimedin claim 4 wherein adjacent bands of the main body are in directvertical alignment.
 7. The box as claimed in claim 1 wherein theplurality of flaps are integral with one another, and the plurality offlaps are formed by at least two pairs of creases running across some ofthe plurality of bands, the creases in each of the pairs being arrangedat an angle relative to one another, and the creases in each of thepairs being arranged to meet at a top edge of the plurality of flaps. 8.A box comprising: (a) a single continuous strip wound in a helicalconfiguration so as to define a main body and a plurality of flaps, themain body including a plurality of bands, and each of the plurality offlaps including at least a portion of a band; (b) wherein adjacent bandsof the main body are in contact with one another and are coupledtogether to render the main body unitary in construction; (c) whereinadjacent bands of the main body engage one another through a matinginterface wherein the mating interface is a stepped mating interface. 9.The box as claimed in claim 8 further comprising an adhesive for fixedlysecuring together adjacent bands of the main body, the adhesive beingdisposed between a region of contact between adjacent bands of the mainbody.
 10. The box as claimed in claim 9 wherein: the single continuousstrip comprises a layer of corrugated material that is disposed betweena first layer of material and a second layer of material, the pluralityof flaps are integral with one another, the plurality of flaps areformed by at least two pairs of creases running across some of theplurality bands, the creases in each of the pairs are arranged at anangle relative to one another, and the creases in each of the pairs arearranged to meet at a top edge of the plurality of flaps.
 11. A boxcomprising: (a) a single continuous strip having a front surface, a rearsurface, a top edge and a bottom edge, the single continuous strip woundin a helical configuration so as to form a plurality of bands whichdefine an entirety of a main body and a plurality of flaps of the box,wherein at least one of the top and bottom edges of the singlecontinuous strip define a mating interface on each of the plurality ofbands through which adjacent bands of the main body engage one anotherand wherein the at least one of the top and bottom edges of the singlecontinuous strip are configured to define the mating interface as astepped mating interface; (b) an adhesive disposed across a surface ofthe stepped mating interface which is exterior to a surface whichdefines an internal cavity of the box wherein the adhesive if disposedalong an entire length of the stepped mating interface between a regionof contact between adjacent bands of the main body such that the steppedmating interface and adhesive fixedly secure together adjacent bands ofthe main body such that adjacent bands are coupled together to renderthe main body of the box unitary in construction, wherein any of theplurality of flaps is defined by at least a portion of one of the bands.12. The box as claimed in claim 11 wherein the single continuous stripcomprises a layer of corrugated material that is disposed between afirst layer of material and a second layer of material.
 13. The box asclaimed in claim 11 wherein the plurality of flaps is dimensioned toselectively enclose a top end of the main body.
 14. The box as claimedin claim 11 wherein the plurality of flaps are integral with oneanother, and the plurality of flaps are formed by at least two pairs ofcreases running across some of the plurality of bands, the creases ineach of the pairs being arranged at an angle relative to one another,and the creases in each of the pairs being arranged to meet at a topedge of the plurality of flaps.
 15. A method of constructing a box, themethod comprising: (a) winding a single continuous strip in a helicalconfiguration so as to define a main body with a plurality of bands; (b)coupling together adjacent bands to secure the shape of the main body:and (c) forming a plurality of flaps.
 16. The method of claim 15 whereincoupling together adjacent bands to secure the shape of the main bodycomprises applying an adhesive to secure the shape of the main body. 17.The method of claim 16 wherein winding a single continuous strip in ahelical configuration so as to define a main body with a plurality ofbands comprises winding a single continuous strip by partiallyoverlapping adjacent bands of the main body.
 18. The method of claim 17wherein winding a single continuous strip by partially overlappingadjacent bands of the main body comprises engaging a stepped matinginterface on adjacent bands of the main body.
 19. The method of claim 16wherein adjacent bands of the main body are in direct verticalalignment.
 20. The method of claim 15, wherein: the single continuousstrip comprises a layer of corrugated material that is disposed betweena first layer of material and a second layer of material, the pluralityof flaps are integral with one another, and forming the plurality offlaps includes forming at least two pairs of creases running across atleast some of the plurality of hands, the creases in each of the pairsbeing arranged at an angle relative to one another, and the creases ineach of the pairs being arranged to meet at a top edge of the pluralityof flaps.
 21. The method of claim 15, wherein: winding a singlecontinuous strip in a helical configuration so as to define a main bodywith a plurality of bands comprises winding a single continuous strip ina helical configuration so as to define a main body having a box bodycomprising four panels provided from the plurality of bands; and forminga plurality of flaps comprises: forming a series of contiguous,horizontal, linear creases in each panel of the box body to create afirst pair of opposing flaps and a second pair of opposing flaps; andforming a pair of diagonal creases in each of the second pair ofopposing flaps such that the creases define a pair of small flaps withineach of the second pair of opposing flaps with each pair of small flapsconfigured to fold inward and the first pair of opposing flapsconfigured to pivot inward and with the first pair of opposing flapsdimensioned to enclose a first end of the box body.